Pocket door assembly

ABSTRACT

The specification discloses a pocket door assembly having a notch or recess in a pocket portion of the frame that allows for use of a protruding handle, such as a doorknob, to be used on a door portion of the assembly. In a second aspect, the specification discloses a latch mechanism for use with pocket doors that may utilize rotary handles, such as standard doorknobs.

CROSS-REFERENCE TO RELATED APPLICATIONS

None.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Embodiments of the invention are directed to an improved pocket doorassembly. More particular, the embodiments of the invention are directedto a pocket door assembly that may use a standard doorknob to facilitateopening and closing of the door.

2. Background of the Invention

A “pocket door” is a door that may be used within homes and officesthat, rather than swinging on a hinge, slides or translates along anupper rail. In a closed position, a pocket door obstructs a doorway. Inorder to open a pocket door, the door itself slides into a “pocket”within walls immediately adjacent to the doorway. Pocket doors may beused in locations where it is disadvantageous for the door to swing.

FIG. 1 shows a related art pocket door assembly as it may be receivedfrom a manufacturer, with the door 40 in its fully open or retractedposition. To close the related art door, the door 40 may be pushed intothe pocket, where a spring biases the door out such that the door itselfmay be grabbed and pulled toward a closed position. Alternatively in therelated art, a latch mechanism 42 may be used, at least initially, topull the door from the retracted position.

FIG. 2, taken substantially along line 2-2 of FIG. 1, illustrates onepossible construction of a frame of a related art pocket door assembly.In particular, this portion of the frame may comprise vertical lumbermembers 44 and 46, which may span the entire height of the frameassembly. Steel channels 48, 50 may be attached to the vertical lumbermembers 44 and 46 respectively, and it is within these channels 48, 50that horizontal lumber cross members 52, 54, 56 and 58 (see FIG. 1) mayattach. After installation of the pocket door assembly, sheet rock maybe placed on top of the horizontal members 52, 54, 56 and 58, andpressed into the shoulder area 60. Thereafter, decorative trim may beattached to the vertical members 44 and 46, such as by the use offinishing nails. U.S. Pat. No. 4,742,645 to Johnston describes anotherpossible construction of the frame portion of the pocket door assemblythat may comprise use of metal channels within which pieces of lumbermay be inserted.

Regardless of the particular construction of the frame, the door 40 ineach of these related art devices is designed and constructed to slidefully within the pocket created by the frame. Because of thisconstruction, it is not possible to have a doorknob or handle mechanismextending in a direction perpendicular to a plane defined by the door,as may be used on doors that rotate about a hinge assembly. Some pocketdoors may attempt to implement door locks, but the lock mechanisms,because of the limited space between the door and the vertical members,are difficult to operate, at best.

Thus, what is needed in the art is a pocket door assembly design thatovercomes these and other problems.

BRIEF SUMMARY OF SOME OF THE PREFERRED EMBODIMENTS

The problems noted above are solved in large part by a pocket doorassembly that provides an indention or notch in the vertical members ofthe frame. The door of the pocket door assembly may comprise a handlethat protrudes outwardly from a plane defined by the door by an amountgreater than a clearance between the door and the vertical framemembers. When the door is opened, the handle translates at leastpartially into a region or area defined by the notch. Opening andclosing the door may thus be accomplished by applying force to thehandle, and thereby sliding the door open or closed.

A second aspect of the preferred embodiments may be a locking mechanismfor use with a pocket door that may be actuated using an off-the-shelfrotary-type doorknob as a handle. The latching mechanism may latch thedoor of the pocket door assembly in a closed position, and the latch maybe released by rotating the doorknob to release the latch.

The various characteristics described above, as well as other features,will be readily apparent to those skilled in the art upon reading thefollowing detailed description, and by referring to the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

For a detailed description of the preferred embodiments of theinvention, reference will now be made to the accompanying drawings inwhich:

FIG. 1 shows a related art pocket door assembly;

FIG. 2 shows a cross-section of a portion of the related art pocket doorassembly;

FIG. 3 illustrates a perspective view of a pocket door assembly, withthe door retracted or open, in accordance with embodiments of theinvention;

FIG. 4 illustrates an elevational view of a pocket door assembly, withthe door extended or closed, in accordance with embodiments of theinvention;

FIG. 5 illustrates a cross-sectional view of a portion of the pocketdoor assembly taken substantially along lines 5-5 of FIG. 3;

FIG. 6A illustrates a cross-sectional view taken substantially alonglines 6A-6A of FIG. 3;

FIG. 6B illustrates a cross-sectional view taken substantially alongline 6B-6B of FIG. 3;

FIG. 7 illustrates an alternative embodiment of the recess;

FIG. 8 illustrates yet another alternative embodiment of the recess;

FIG. 9 illustrates a cross-sectional view of a latch assembly inaccordance with embodiments of the invention;

FIG. 10 illustrates a striker plate in accordance with embodiments ofthe invention; and

FIG. 11 illustrates an exemplary contact of a handle connection memberwith bolt arm.

NOTATION AND NOMENCLATURE

Certain terms are used throughout the following description and claimsto refer to particular system components. This document does not intendto distinguish between components that differ in name but not function.

In the following discussion and in the claims, the terms “including” and“comprising” are used in an open-ended fashion, and thus should beinterpreted to mean “including, but not limited to . . . ”. Also, theterm “couple” or “couples” is intended to mean either an indirect ordirect connection. Thus, if a first device couples to a second device,that connection may be through a direct connection, or through anindirect connection via other devices and connections.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 3 illustrates a pocket door assembly 100 constructed in accordancewith embodiments of the invention. In particular, the pocket doorassembly 100 may comprise a frame 110 that may generally comprise adoorway portion 112 and a pocket portion 114. The pocket door assembly100 may further comprise a door 116 slidingly mounted within the frame110, and in particular, the door 116 may be mounted to a horizontalheader assembly 113 which may span substantially an entire upper lengthof the pocket door assembly. The perspective view of the pocket doorassembly 100 of FIG. 3 illustrates the door 116 in its retracted or openposition. By contrast, the elevational view of the pocket door assembly100 of FIG. 4 shows the door 116 in its extended or closed position.Before proceeding, it should be understood that the pocket door assembly100 illustrated in FIGS. 3 and 4 is as it may be received from a doormanufacturer prior to installation, and thus the pocket door assembly isnot shown with solid walls covering the pocket portion 114, as would bethe case after final installation.

FIG. 5, taken substantially along line 5-5 of FIG. 3, illustrates thecoupling of vertical members 122 and 124 to various horizontal membersin accordance with at least some embodiments of the invention. Thevertical members 122 and 124 may define, in part, an opening throughwhich door 116 may slide or translate. A distance between the door 116and each vertical member may define a clearance 117. Each verticalmember 122, 124 may have coupled thereto a metallic member 136, 138,possibly having an “L” shaped cross-section. The metallic elements 136and 138 may be aluminum; however, other materials may be equivalentlyused. In the cross-section illustrated in FIG. 5, the horizontal members126A and 126B couple to the metallic members 138 and 136 respectively.In at least some embodiments, the horizontal members 126 are made ofwood or lumber, and thus the coupling between the horizontal members 126and the metallic members 122, 124 may be by any suitable connectionmechanism, such as screws, bolts, adhesives, and the like. Inalternative embodiments, the vertical members 122 and 124 may be createdas one assembly, for example using injection molded plastic techniques.In these embodiments, the metallic members 136 and 138 may not be used,and the structural members forming the pocket may not necessarily behorizontal. Although FIG. 5 shows only horizontal members 126A, Bcoupled to the vertical members, it will be understood that theremaining horizontal members, as well as the brace member 134, maycouple in a similar manner.

As is illustrated by FIG. 5, the horizontal members may not preciselyalign with an outer surface of the vertical members 122 and 124. Thisforms a shoulder region 140 into which wall board 142 may be placed. Fordecorative purposes, trim or molding 144 may be attached to the verticalmembers 122 and 124 (not shown attached to 122). It is noted that thewall board 142 and molding 144 are not shown in FIG. 3, but wereincluded in FIG. 5 for purposes of explaining how these materials maycouple to the pocket door assembly 100.

As illustrated in FIGS. 3 and 4, the pocket door assembly 100 of thevarious embodiments of the invention may have an indention or notch 118.The notch 118 may be defined by an offset in the vertical members 122,124, as well as corresponding offsets in the metallic members 136, 138,if used, the offset extending toward a back 129 (FIG. 3) of the pocket.As best shown by the door 116 in the retracted or open position asillustrated in FIG. 3, the notch 118 allows for use of a handle 120extending outwardly from a plane defined by the door a distance greaterthan the clearance 117 between the door 116 and vertical members 122,124. The handle 120 may reside, at lest partially, in an area defined bythe notch 118 when the door 116 is substantially within the pocket.Although the notch 118 shown in FIGS. 3 and 4 has three sides 119A, B, C(FIG. 4), any shape notch 118 is within the contemplation of thisinvention. For example, FIG. 7 illustrates an embodiment where the notch118 is rectangular. Likewise, FIG. 8 illustrates an embodiment where thenotch is semi-circular.

The pocket portion 114 of the pocket door assembly 100 may comprise aplurality of horizontal members 126, 128, 130 and 132. Although notspecifically shown in FIG. 3, there may be a corresponding set ofhorizontal members on the opposite side of door 116, and thesehorizontal members may define, in part, the cavity or pocket of thepocket portion 114. In at least some embodiments, the horizontal members126, 128, 130 and 132 may be lumber, and may be attachments points forinstallation of sheet rock or other wall-board material. At least someof the horizontal members, for example horizontal member 128 and 130,may couple to brace member 134, which may simply reinforce the notch118.

FIG. 6A, taken substantially along line 6A-6A of FIG. 3, illustratesthat, in at least some embodiments, a lower portion of the pocketassembly 114 may comprise rollers, for example rollers 146 and 148. FIG.6B, taken substantially along line 6B-6B of FIG. 3, illustrates therollers 146, 148 from a different perspective. Rollers 146 and 148 mayhelp keep the door 116 centered between the horizontal and verticalmembers, thus making opening and closing of door 116 easier as well aslessening the likelihood that the door 116 makes unwanted contact withother stationary components, which may damage the door and/or makeopening and closing the door difficult.

In installations where door 116 need not be latched closed, for exampleif the pocket door assembly 100 provides access to a linen closet, itmay not be necessary to provide a latch mechanism for the door 116.However, in some installations, for example a pocket door assembly 100on an entrance to a bedroom or bathroom, the door 116 of the pocket doorassembly 100 may comprise a latch mechanism 200 (partially seen in FIG.3) that may hold the door in the extended or closed position, and whichmay also be utilized to lock the door.

FIG. 9 shows a cross-sectional view of the latch mechanism 200, whichmay be utilized with a striker plate 220 as illustrated in FIG. 10, inaccordance with embodiments of the invention. The latch mechanism 200may comprise an elongated outer housing 202 having an axis 204. Thelatch mechanism may be coupled to the door 116 by inserting the latchmechanism 200 into a hole, possible of circular or semi-circularcross-section (not shown), in the door 116, where an axis of the holeand latch mechanism 204 may be substantially aligned with a direction oftranslation of the door 116. The latch mechanism 200 may comprise a bolt206 that slides within a bolt cavity or housing 208. Spring 210 may biasthe bolt to an extended position, with pin 212 retaining the bolt 206within the housing 208. In the rest position, the bias spring 214 maybias the bolt housing 208 against a lower portion of the outer housing202. As the door 116 is translated out of the pocket portion 114, alatch end 207 of the bolt 206, in particular a curved strike area 216,may contact the cross-bar 218 of the strike plate 220. Initial contactwith the strike area 216 may be made near the tip 222 of the bolt 206.The contact may progress from the tip 222 toward the slot 224.

The contact of the bolt 206 with the cross-bar 218, and progress of thecontact, may produce two movements of the bolt 206. First, upon initialcontact of the bolt 206 with the cross-bar 218, the bolt 206 maycompress spring 20 translating or telescoping the bolt 206 into the bolthousing 208. Somewhat simultaneously, contact of the bolt 206 with thecross-bar 218 may pitch the bolt housing 208 (as indicated by arrow 226,and as illustrated in dashed lines). Pitching of the bolt housing 208may be allowed by a hinge 230, having a stationary portion coupled tothe outer housing 202, and a rotating portion coupled to a bolt arm 232.As the contact point moves from the tip 222 toward the slot 224, thelatch end 207 of the bolt 206 may extend into an aperture 228 of thestrike plate 220 (FIG. 10). As a component of an applied force along anaxis of bolt 206 begins to diminish, i.e. the contact point moves closerto the slot 224, the bolt 206 may telescope out of the bolt housing 208under force applied by spring 210, at which point the slot 224 may slideover a corresponding structure coupled to the doorway portion 112 of theframe, such as cross-bar 218 (FIG. 10). With slot 224 engaging cross-bar218, the latch mechanism 200 may hold the door in the closed position.To unlatch the latch assembly 200, a rotary handle 120, such asillustrated in FIG. 3, may be rotated. A handle connection member,extending through the door 116 substantially perpendicular to the planedefined by the door 116 and connecting the handle members on each sideof the door, in response to rotation of the handle may rotate the boltassembly housing 208, possibly by application of force on the bolt arm232. Locking of the door 116 with latch 200 may be accomplished with adoorknob or handle 120 that prevents rotation in the locked position.

FIG. 11 illustrates an interaction between the handle connection memberand the bolt arm 232. In particular, FIG. 11 shows a partialcross-sectional elevational view of the latch assembly 200 with the boltarm 232 pitched by contact of a handle connection member 234. In a restposition, the bolt arm 232 may rest substantially on an upper surface ofthe handle connection member 234, where that surface is substantiallyhorizontal (the rest position indicated in FIG. 11 by the shadowedconnection member in dashed lines). By rotation of the handle (not shownin FIG. 11), the handle connection member likewise may rotate, therebypitching the bolt housing 208. While some off-the-shelf doorknobs have asubstantially square handle connection member, as shown in FIG. 11,other off-the-shelf doorknobs have a handle connection member with a “U”shape (not shown). Operation of the latch assembly in this situation issubstantially the same as described above, except upper portions of the“U” shaped handle connection member contact the bolt arm 232. For thosedoorknobs that implement locking functionality with the “U” shapedhandle connection member, a locking rod may reside within a valley ofthe “U” shaped member, and in this case, the bolt arm 232 may be groovedor arched to allow the bolt arm to rest on the “U” shaped member inspite of the locking rod.

The above discussion is meant to be illustrative of the principles andvarious embodiments of the present invention. Numerous variations andmodifications will become apparent to those skilled in the art once theabove disclosure is fully appreciated. For example, the frame 110 of thepocket door assembly may be made of injection molded plastic, withportions thereof reinforced by metallic members. Further, while onlythree variations for the recess 118 are shown, one of ordinary skill inthe art, now understanding the concept of creating a recess and using aprotruding handle, such as knob 120, could easily fashion numerousvariations for the configuration of the recess 118, and each of thesevariations falls within the contemplation of this invention. Further, itmay be possible to have a door that does not slide completely within thepocket, and in this case a notch may not be required in spite of using ahandle that extends a distance greater than the clearance between thedoor and the vertical member. With regard to the rollers 146 and 148illustrated in FIGS. 6A and 6B, being circular cylinders having theiraxis aligned with the vertical members 122 and 124, one of ordinaryskill in the art, now understanding the benefits of providing rollingsurfaces near a bottom of the door 116, could easily implement manyvariations, such as ball bearings with suitable housings, and the like.Further, though the embodiments of the invention described show notchesformed on both sides of the door 116, the benefits of the invention maybe equivalently obtained by a notch 118 on only one side, andcorrespondingly a handle that extends on only one side of the door. Itis intended that the following claims be interpreted to embrace all suchvariations and modifications.

1. A pocket door assembly comprising: a frame comprising a doorwayportion defining an aperture, and the frame also comprising a pocketportion defining a cavity; a vertically oriented door slidingly coupledto the frame, the door adapted to slide into the cavity defined by thepocket portion of the frame; a handle coupled to the door and extendingoutward from the door a distance greater than a clearance between thedoor and a first vertical member of the pocket portion of the frame; alatch assembly coupled within the door and in operational relationshipto the handle; and wherein the latch assembly latches the door in aclosed position, and wherein the handle releases the latch assembly froma latched position.
 2. The pocket door assembly as defined in claim 1further comprising: a notch in the pocket portion of the frame at aboundary between the pocket portion and the aperture, the notch atapproximately a same elevation as the handle; and wherein the handleresides at least partially within an area defined by the notch when thedoor is open.
 3. The pocket door assembly as defined in claim 2 whereinthe pocket portion further comprises: a second vertical member, thefirst and second vertical members defining an opening through which thedoor slides into the cavity; and said notch formed, at least in part, byan offset in one of the first and second vertical members.
 4. The pocketdoor assembly as defined in claim 3 wherein the notch is formed bycorresponding offsets in both the first and second vertical members. 5.The pocket door assembly as defined in claim 2 wherein the notch issemicircular.
 6. The pocket door assembly as defined in claim 2 whereinthe notch is defined by three straight sides.
 7. The pocket doorassembly as defined in claim 2 wherein the notch is rectangular.
 8. Thepocket door assembly as defined in claim 2 wherein the notch is definedby two straight sides.
 9. The pocket door assembly as defined in claim 1wherein the handle extends outward in both directions from the door. 10.The pocket door assembly as defined in claim 9 wherein the handlefurther comprises a rotary doorknob.
 11. (canceled)
 12. The pocket doorassembly as defined in claim 1 wherein the latch assembly furthercomprises: an outer housing; a bolt mounted within the outer housing,the bolt having a curved strike area and a slot, the strike area inoperational relationship to the slot, and wherein the bolt has an axisaligned substantially with a direction of translation of the door; andwherein latching of the door pitches the bolt until the slotmechanically mates with a corresponding structure on the doorway portionof the frame.
 13. The pocket door assembly as defined in claim 12wherein the latch assembly further comprises: a bolt housing hingedlycoupled within the outer housing, the bolt slidingly coupled within thebolt housing; a first spring within the bolt housing biasing the bolt toan extended position; and a second spring mounted within the outerhousing, the second spring biasing the bolt housing against an insideportion of the outer housing.
 14. The pocket door assembly as defined inclaim 13 wherein the bolt housing further comprises: a rotary hingeportion, the rotary hinge portion coupled to a stationary hinge portionon the outer housing; a bolt arm coupling the rotary hinge portion to abolt cavity, the bolt and first spring within the bolt cavity; andwherein the bolt arm is adapted to be a point of contact for rotationalforce that pitches the bolt housing and releases the slot of the boltfrom the corresponding structure on the doorway portion of the frame.15. The pocket door assembly as defined in claim 14 wherein the bolt armis further adapted to operationally couple to a rotary door handle. 16.A pocket door assembly comprising: a horizontal header assembly; a doorslidingly mounted to the horizontal header assembly; a first and secondvertical members coupled to the horizontal header assembly, the firstand second vertical members defining an opening; a first plurality ofcoplanar members coupled to the first vertical member, a plane definedby the first plurality of coplanar members substantially parallel to aplane defined by the door; a second plurality of coplanar memberscoupled to the second vertical member and extending a same direction asthe first plurality of coplanar members, a plane defined by the secondplurality of coplanar members substantially parallel to the planedefined by the door; wherein the first and second vertical members, andthe first and second plurality of coplanar members, define a pocket intowhich the door slides; a handle coupled to the door and extendingsubstantially perpendicularly from the plane defined by the door, thehandle extending a distance greater than a clearance between the doorand one of the first and second vertical members; a latch assemblycoupled within the door and in operational relationship to the handle;and wherein the latch assembly latches the door in a closed position,and wherein the handle releases the latch assembly from a latchedposition when the handle is rotated.
 17. The pocket door assembly asdefined in claim 16 further comprising: one of the first and secondvertical members defining an indention, the indention having adeflection toward a back of the pocket; and wherein the handle residesat least partially in an area defined by the indention when the door issubstantially within the pocket.
 18. The pocket door assembly as definedin claim 17 wherein the indention is rectangular.
 19. The pocket doorassembly as defined in claim 17 wherein the indention is semicircular.20. The pocket door assembly as defined in claim 17 wherein theindention is defined by three straight sides.
 21. The pocket doorassembly as defined in claim 17 wherein the indention is defined by twostraight sides. 22-25. (canceled)
 26. A latch assembly for a pocket doorcomprising: an elongated outer housing having an axis; a bolt mountedwithin the outer housing, the bolt having a curved strike area, andwherein the bolt has an axis substantially parallel to the axis of theelongated outer housing when the bolt is in a rest position; anelongated bolt housing hingedly mounted within the elongated outerhousing, the bolt slidingly coupled within the bolt housing; a firstspring within the bolt housing biasing the bolt to an extended position;and a second spring mounted within the elongated outer housing, thesecond spring biasing the bolt housing against a lower portion of theouter housing in the rest position wherein the bolt pitches when a forceis applied to the strike area and wherein the bolt's axis becomessubstantially parallel with the axis of the elongated outer housing whenthe latch assembly latches.
 27. The latch assembly as defined in claim26 wherein the elongated bolt housing further comprises: a rotary hingeportion, the rotary hinge portion coupled to the a stationary hingeportion on the elongated outer housing; a bolt arm coupling the rotaryhinge portion to a bolt cavity, the bolt and first spring within thebolt cavity; and wherein the bolt arm is adapted to be a point ofcontact for rotational force to release the latch assembly.
 28. Thelatch assembly as defined in claim 27 wherein the bolt arm is furtheradapted to operationally couple to a rotary door handle.
 29. The latchassembly as defined in claim 26 wherein the bolt telescopes, at leastpartially, into the bolt housing and compresses the first spring whenthe location of the force application is near a tip of the bolt.
 30. Thelatch assembly as defined in claim 29 wherein the bolt telescopes out ofthe bolt housing as a location of the force application approaches aslot, the slot in operational relationship to the strike area.